Dual chamber airbag cushion

ABSTRACT

An airbag cushion has two chambers to permit the front chamber to inflate less rapidly than the back chamber for cushioning the head of an occupant in a vehicle with less force than the chest of an occupant is cushioned by the back chamber.

TECHNICAL FIELD

The present invention relates generally to the field of automotiveprotective systems. More specifically, the present invention relates toinflatable airbags for automobiles.

BRIEF DESCRIPTION OF THE DRAWINGS

Understanding that drawings depict only typical embodiments of theinvention and are not therefore to be considered to be limiting of itsscope, the invention will be described and explained with additionalspecificity and detail through the use of the accompanying drawings aslisted below.

FIG. 1 is a perspective view of an airbag module and its airbag cushionwith a partial cut-away to show the tethered partition.

FIG. 2A is a side view of an embodiment of the airbag cushion of FIG. 1deployed with its interior shown in phantom.

FIG. 2B is a cross-sectional view of the deployed airbag cushion of FIG.1.

FIG. 3A is a cross-sectional view of the airbag cushion shown in FIG. 1upon deployment in front of an occupant.

FIG. 3B is a cross-sectional view of the occupant shown in FIG. 3A asthe front chamber provides cushioning for the occupant's head.

FIG. 4 is a cross-sectional view of an another embodiment of a deployedairbag cushion with a partition between a front chamber and a backchamber

FIG. 5A is a side view of an embodiment of the airbag cushion of FIG. 4deployed with its interior shown in phantom.

FIG. 5B is a cross-sectional view of airbag cushion shown in FIG. 4.

FIG. 6 is a cross-sectional view of an another embodiment of a deployedairbag cushion with a partition between a front chamber and a backchamber and also featuring closeable safety vents.

FIG. 7A is a perspective view of one of the closeable safety vents shownin FIG. 6 while it is open.

FIG. 7A is a perspective view of one of the closeable safety vents shownin FIG. 6 after it has been closed.

FIG. 8A is a perspective view of the airbag cushion shown in FIG. 6 thatis partially inflated as it has encountered an obstruction such as anoccupant who is out of position.

FIG. 8B is a perspective view of the airbag cushion shown in FIG. 6 whenin the same position as the airbag cushion shown in FIG. 8A.

FIG. 8C is a cross-sectional view of the airbag cushion shown in FIG. 6.

FIG. 9A is a perspective view of another embodiment of an airbag moduleand its airbag cushion with a partial cut-away to show a tetheredpartition, a tethered diffuser and closeable safety vents that are open.

FIG. 9B is a perspective view of the airbag cushion shown in FIG. 9Awith a partial cut-away to show the safety vents that are closed, asviewed from the front region.

FIG. 9C is a perspective view of the airbag cushion shown in FIGS. 9A-9Bwith a partial cut-away to show the safety vents that are closed, asviewed through the windshield.

FIG. 10 is a perspective view of of another embodiment of an airbagcushion which differs from the embodiment shown in FIGS. 9A-9C in thatthe diffuser is sewn to the partition instead of being tethered.

FIG. 11 is a cross-sectional view of an another embodiment of a deployedairbag cushion with a partition between a front chamber and a backchamber and also featuring closeable safety vents in the front chamber.

FIG. 12A is a cross-sectional view of the airbag cushion shown in FIG. 9when an occupant's head has caused the front chamber to only partiallyinflate.

FIG. 12B is a cross-sectional view of the airbag cushion shown in FIG. 9with a front chamber that is inflated as it has not encountered anobstruction.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Described below are embodiments of an airbag cushion. As those of skillin the art will appreciate, the principles of the invention may beapplied to and used with a variety of airbag deployment systemsincluding frontal driver and passenger airbags. Such airbag cushions arefrequently located in an instrument panel and directly in front of anoccupant. During a collision, an airbag cushion inflates and deploysthrough a cosmetic cover. The airbag cushion deploys towards theoccupant and provides a restraint.

Because an upper torso has a mass that is significantly larger than themass of an occupant's head, more energy is required to restrain theupper torso. To avoid restraining an occupant's head more than isnecessary and to minimize neck injuries, airbag cushions are disclosedthat deliver less force to an occupant's head than is delivered to anoccupant's upper torso. The embodiments disclosed herein feature anairbag with two distinct chambers. One chamber is expanded by receivinginflation gas directly from an inflator while the other chamberindirectly receives inflation gas. In the depicted embodiments, apartition divides an interior of an airbag cushion to provide a backchamber for restraining an occupant's torso receives inflation gas thatreceives gas directly from an inflator and a front chamber forrestraining an occupant's head that receives gas through the partition.

Embodiments are also disclosed that provide mechanisms to prevent fullinflation of the front chamber and/or the back chamber. Full inflationof an airbag is not always desired. For example, partial inflationoffers optimal protection when the occupant being protected by theairbag cushion is a child, a baby in a rear facing car seat or an adultpositioned too close to the air bag cushion. Such conditions arereferred to as out-of-position conditions. Embodiments described belowprovide an airbag cushion that responds to an occupant's position andvents accordingly to avoid excessive deploying impact. These embodimentshave a closeable opening for venting gas referred to as an optionallycloseable vent for out-of-position (OOP) conditions such as a cinch ventor a closeable vent. Each closeable vent may be closed via a componentsuch as a control tether or cord. Numerous embodiments of controltethers are disclosed including control tethers configured toincrementally close the vent. The tether may be connected at one end toa vent and at an opposing end elsewhere within or on the cushion. In oneembodiment, the tether has a length that is greater than 180 mm. Such alengthy tether allows the airbag cushion to be tethered adjacent to thetether so that it can pull the partition in so that it has a deep drawfor deep cushioning of an occupant's head.

If an occupant is in close proximity to the deploying airbag andrestricts normal inflation, the closeable vent remains open and allowsgas to rapidly escape. If the occupant is in a normal position andinflation is unrestricted, the tension pulls on the tether to quicklyclose the closeable vent. Closure retains gas for normal occupantrestraint. Thus, the closeable vent may be used as a variable feature inout-of-position conditions and in normal restraint conditions. In thismanner, the airbag cushion is sensitive to obstructive expansion of thecushion.

With reference now to the accompanying figures, particular embodimentsof the invention will now be described in greater detail. One embodimentof airbag module 100 is shown in FIG. 1, FIGS. 2A-2B, FIGS. 3A-3Bcomprising an airbag cushion 101. FIGS. 3A-3B show an occupant 30 withairbag cushion 101 deployed through the instrument panel 40 againstwindshield 60.

Airbag cushion 101 has an interior 102 defined by cushion membrane 110.Interior 102 is divided into a back chamber 102 b and a front chamber102 f. In the depicted embodiment of airbag cushion 101, front chamber102 f is attached by seams 104 and features discrete vents 106. Backchamber 102 b has a throat 108 that is sized to be fitted around theinflator 120.

Cushion membrane 110 has an interior surface 111 and an exterior surface112. Cushion membrane 110 may have any suitable shape. The depictedembodiments have a front region 113 configured to be directed toward anoccupant in a vehicle when the cushion is deployed. Front regioncomprises an upper portion 113 u and lower portion 113 l. Cushionmembrane 110 also comprises a top region 114, bottom region 116 andopposing side regions 118. Top region 114 is above upper portion 113 uof front region 113. Bottom region 116 is below lower portion 113 l offront region 113. When deployed, bottom region 116 has a portion thatwraps around instrument panel 40 and another portion that extends awayfrom the instrument panel towards the occupant's thighs.

A partition 130 extends within interior 102 laterally between sideregions 118 of airbag cushion 101 to define back chamber 102 b and frontchamber 102 f in interior 102. Back chamber 102 b is sized to beinflated to a substantially larger volume than front chamber 102 f.Front chamber 102 f is defined by partition 130, top region 114 of thecushion membrane, upper portion 113 u of front region 113 of the cushionmembrane, and side regions 118. Back chamber 102 b is defined bypartition 130, top region 114, bottom region 116, and side regions 118.Back chamber 102 b is positioned to receive inflation gas directly frominflator 120 via throat 108. This configuration enables front chamber102 f to be supported by back chamber 102 b such that front chamber 102f is directed to an occupant's head.

As shown in FIGS. 2A-2B and FIGS. 3A-3B, back chamber 102 b is boundedby the reaction area of the windshield 60 and the instrument panel 40 toensure stability of cushion 101 during restraint of an occupant. Frontchamber 102 f extends up to windshield 60 to ensure proper restraint ofthe head of large occupants. However, the area of cushion 101 that is incontact with windshield 60 either does not include front chamber 102 for is the transition point between front chamber 102 f and back chamber102 b. Back chamber 102 b has a bottom portion which, when inflated, isthe region extending from front region 113 to top region 114. Backchamber 102 b also has a top portion above its bottom portion. In thedepicted embodiment, the top portion is not narrower than the bottomportion so that the cushioning provided is stable and to optimallyprotect the occupant's head from windshield 60. Also the top portion ofback chamber 102 b is depicted as being at least as wide as frontportion 102 f.

Partition 130 has triangular portions 137 a-d that converge at center138 such that partition 130 has a pyramidal shape. Triangular portion137 a is opposite from top region 114, triangular portion 137 b isopposite from lower portion 113 l of front region 113 and bottom region116, and portions 137 c-d are opposite side regions 118. Front chamber102 f may be viewed as having two areas, an outer portion 103 o and aninner portion 103 i. A plane cutting through the cross-sectional viewprovided by FIG. 2A that corresponds with a pyramid base as defined byportions 137 a-d, bisects front chamber 102 f to define an inner portion103 i and outer portion 103 o, which extends beyond back chamber 102 band has a cross-sectional shape that is roughly triangular with arounded corner between a top leg that is shorter than its bottom leg.

Front chamber 102 f receives inflation gas through partition 130 fromback chamber 102 b. In the embodiment depicted in FIG. 1, FIGS. 2A-2Band FIGS. 3A-3B, partition 130 has internal vents 136 to permitinflation gas to flow from back chamber 102 b to front chamber 102 f.However, front chamber 102 f may also receive inflation gas throughpartition 130 from back chamber 102 b due to the permeability of thepartition. Both embodiments enable the front chamber to inflate lessrapidly than the back chamber to cushion the head of an occupant in avehicle. However, internal vent 136 is located in portion 137 a, whichis the closest portion of partition 130 to inflator 120 so thatinflation of front chamber 102 f is not delayed as long as it would beif the inflator was only in portion 137 b. The same is true for apartition that permits the transmission of gas based on permeability. Toavoid excessively delaying the inflation of front chamber 102 f, frontregion 113 is not attached to partition 130 with a releasable tether.

Tether 134 has ends 135 a-b, which are respectively attached to a centerpoint 138 of partition 130 and cushion membrane 110, at a location nearthroat 108. As airbag cushion 101 expands, as shown in the embodimentdepicted in FIG. 1, FIGS. 2A-2B and FIGS. 3A-3B, tether 134 keepspartition 130 from expanding. When airbag cushion module 100 isdeployed, partition 130 has a pyramidal shape with the peak attached totether 134. In the embodiment depicted in FIG. 1, FIGS. 2A-2B and FIGS.3A-3B, partition 130 is essentially a portion of cushion membrane 110that is drawn by tether 140 to decrease the volume available in backchamber 102 b so that front chamber 102 f can have a larger volume.

In one embodiment, airbag cushion 101 has a configuration such that backchamber 102 b extends further toward the occupant than front chamber 102f than back chamber. FIG. 2B shows lower portion 113 l of front region113 extending just slightly further toward the occupant than upperportion 113 u of front region 113. In another embodiment, back chamber102 b and front chamber 102 f extends about the same distance toward anoccupant. For these two embodiments, the back chamber extends no furthertoward the occupant than the front chamber. In an additional embodiment,the front chamber extends further toward the occupant when fullyinflated but does not reach the occupant before the back chamber becausethe back chamber more rapidly inflates. In these embodiments, the rapidinflation of the back chamber ensures that the front chamber issupported while providing distinct cushioning effects for the head andthe torso.

The front chamber and the back chamber generally have about the samewidth, which ensures that the head is cushioned more gently across theairbag cushion even when the occupant is not centrally seated. For theembodiment depicted in FIG. 1, however, the center of front portion 102f will have deeper cushioning in its center at the location of theattachment of tether 134 to partition 130.

Other embodiments are also disclosed herein of dual chamber airbagcushions such as the embodiment shown at 101. Elements that areidentical or have a corresponding relationship with elements identifiedabove with respect to cushion 101 are increased by 100 or a multiplethereof.

In the embodiment depicted in FIG. 4 and FIGS. 5A-4B, identified asairbag module 200, airbag cushion 201 has a partition 230 with ends 232a-d that are attached by seams 233 a-d to cushion membrane 210. Moreparticularly, ends 232 c-d are attached to side regions 218 and ends 232a-b are respectively attached to top region 214 and to front region 213at the transition between upper portion 213 u of front region 213 andlower portion 213 l of front region 213. Because ends 232 a-d areattached to cushion membrane 210, a tether is not featured. However, atether could also be used in combination with this embodiment to moresecurely maintain the center of partition 230 in a desired position. Inother embodiments, the tether could be eliminated by sewing thepartition at a center location to top region 214 and bottom region 216.

Airbag cushion 201 has a discrete vent 206 just like airbag cushion 101has a discrete vent 106 for venting out of front chamber 102 f. However,airbag cushion 201 also features a discrete vent 207 for ventinginflation gas out of back chamber 102 b. Discrete vents for ventinginflation gas may also be located in the back chambers of the otherembodiments described herein.

Partition 230 has portions 237 a-b that converge at center fold 238.Portion 237 a is opposite from top region 214 and portion 237 b isopposite from lower portion 213 l of front region 213 and bottom region216. Note that portion 237 a is more horizontal with respect to thelongitudinal axis of a vehicle than portion 237 b while portion 237 b ismore vertical with respect to the longitudinal axis of a vehicle thanportion 237 a. Front chamber 202 f may be viewed as having two areas, anouter portion 203 o and an inner portion 203 i. A plane cutting throughthe cross-sectional view provided by FIG. 4B, bisects front chamber 202f to show that inner portion 203 i has a triangular shape and outerportion 203 o extends beyond back chamber 202 b and has a shape that isroughly triangular with a rounded corner between a top leg that isshorter than its bottom leg. This configuration provides for deepcushioning of an occupant's head and separates the protection providedby back chamber 202 b. FIG. 6 is a perspective view which shows airbagcushion 301 of airbag module 300 with closeable safety vents 350 a-b.Closeable safety vents 350 a-b are shown in FIG. 6 after control tethers370 a-b have been pulled taut by expansion of the cushion due to thepressure of the gas in airbag cushion 301.

Note that the embodiment of the airbag module depicted in FIG. 6 andFIGS. 8A-8C has a front chamber 302 f that receives inflation gasthrough partition 330 from back chamber 302 b without internal vents aspartition 330 has a permeability designed to enable gas transfer.However, partition 330 can also be replaced with a partition that hasinternal vents. Either embodiment enables the front chamber to inflatemore gently than the back chamber to cushion the head of an occupant ina vehicle.

When airbag cushion 301 deploys, inflation gas passes from back chamber302 b through partition 330 and into front chamber 302 f. Discrete vent306 provides an outlet for the inflation gas from front chamber 203 f.When airbag cushion 301 deploys without encountering obstruction in thedeploying path, gas rapidly transfers through partition 330, into frontchamber 302 f and then out of discrete vent 306. Discrete vents may beoptional in certain cushion embodiments based on venting requirements.The locations for discrete vents and closeable safety vents may vary asdoes the number of vents.

When an occupant is in a normal seating position so that airbag cushion301 can fully expand before impacting the occupant, airbag cushionappears as shown in FIG. 6 and FIG. 8C. In this manner, the occupant 30benefits from the full restraint capability of the airbag cushion 301.

When an occupant is out of position, airbag cushion 301 appears as shownin FIGS. 8A-8B. When the initial breakout of the airbag cushion 301occurs, closeable cinch vents 350 a-b are open and, in the depictedembodiment, extend from the airbag cushion 301. Because cushion 301 isinitially in a folded condition, at initial breakout (such as theinitial 7 milliseconds), closeable cinch vents 350 a-b are initiallynon-functional. Because an occupant is not positioned directly in frontof the airbag cushion 301 in FIGS. 8A-8B, cushion 301 unfolds and isallowed to pressurize normally. In FIGS. 8A-8B, tethers 370 a-b whichrespectively correspond with cinch vents 350 a-b are pulled taut and gasflow through cinch vents 350 a-b is restricted. In FIG. 6 and FIG. 8C,cinch vents 350 a-b are completely closed, the gas vents through thefixed vents 360 a-b, and normal restraint is provided to the occupant.

Other examples of embodiments of closeable vents are also disclosed inU.S. patent application Ser. No. 11/589,316 titled AIRBAG CUSHION WITHOPTIONAL VENTING FOR OUT-OF-POSITION CONDITIONS which was filed on Oct.27, 2006 and was published as U.S. Patent Publication No. 2007/0216146.application Ser. No. 11/589,316 is hereby incorporated by reference. Theparticular embodiment of the closeable safety vent shown in FIG. 5 at350 a-b is also referred to as a cinch vent in application Ser. No.11/589,316.

As shown in FIGS. 7A-7B and FIGS. 8A-8B, each safety vent 350 comprisesa cinch tube 352 having a base end opposite from a terminal end. Atether holder, such as sleeve 353, with holes referred to as sleeveapertures 354, may be used to hold a vent portion 373 of tether 370.Vent aperture 358 is defined by the inner diameter of rim 351 of tube352. Cinch vent 350 may be embodied with a generally cylindrical shape.The cinch tube may have any suitable shape such as rectangular,triangular, or polygon shapes. The cinch tube may be embodied with aheight that is sufficient to achieve desired closure. In one embodiment,the cinch tube has height which is about half of its diameter. Selectingan appropriate height to diameter ratio permits the cinch tube to closeduring cinching without resistance from cushion membrane tension. Thedesign permits the cinch tube to be a low-stress element in the cushionassembly which is helpful during unfolding of the cushion andpressurization. The cinch tube may comprise a nylon woven fabric-type orother suitable material known in the art.

Referring to FIGS. 7A-7B, safety vent 350 is shown in more detail.Tether 370 has an end that is formed into a loop and a vent portion 373around the majority of the perimeter of cinch tube 352. Cinch tube 352has a sleeve 353 which holds vent portion 373 of tether 370. Ventportion 373 enters sleeve 353 via sleeve aperture 354. Otherconfigurations can also be utilized such as stitching to hold the end oftether to cinch tube 352 or the tether could extend through the sleevewith both ends attached together to the cushion membrane at tetherattachment 379. As shown in FIG. 7B, sleeve 353 is gathered togetherwhen tether 370 has been pulled taut. By causing cinch tube 352,particularly rim 351, to collapse on itself, safety vent 350 is closedwithout necessitating closure of the base end of the cinch tube, suchthat the terminal end, including rim 351, is at least partially withinthe interior of the inflatable airbag cushion after the aperture 358becomes at least partially closed. In other embodiments, sleeve 353features numerous apertures to facilitate cinching or a plurality loopsor tabs may collectively act as a tether holder.

When inflatable airbag cushion 301 is fully inflated, the inflationcreates a cushion membrane tension that fully extends the first end ofthe tether 370 coupled to the interior surface 311 of cushion membrane310 until reaching the maximum length of tether 370, thereby pulling onthe first end of the tether 370 and closing the closeable safety vent.The configuration of the cinch tube 352, such as the ratio of its heightto the diameter of rim 351, in combination with tether 370, permits rim351 of aperture 358 to be brought together without having to overcomeresistance from the cushion membrane tension around closeable safety350.

Tether 370 is configured to move with the expansion of airbag cushion301 to enable vent portion 373 to close closeable safety vent 350. FIG.8B shows the end of tether 370 opposite from closeable safety vent 350,which is connected to cushion membrane 310 via a tether attachment 379and which is part of or extends from membrane 310 of airbag cushion 301.As shown in FIG. 8B, tether attachment 379 serves as an anchor for anend of tether 370. In another embodiment, the tether attachment isstitching between cushion membrane 310 and tether 370. In anotherembodiment, tether 370 is an integral extension of either cushionmembrane 310 or cinch tube 352. Alternatively, tethers 370 a-b arereplaced by a single tether that is attached at its opposing ends tosafety vents 350 a-b and is moveably anchored to cushion membrane 310via a tether attachment which is essentially a loop that permitsmovement of the single tether. The tether attachment may be disposedelsewhere such as proximate to a different portion of interior surface311. Alternatively, the tether attachment may be a portion of exteriorsurface 312. For example, the tether attachment may be at the lowerportion 313 l of front region 313.

Thus, tether 370 may extend through the interior 302 of the airbagcushion 301 or may be positioned exterior to the airbag cushion 301. Thelocation of the tether attachment 379 depends on module deploymentangle, vehicle interior geometry, and cushion fold type. The tether 370may comprise a nylon material or other suitable material known in theart.

Referring to FIG. 6 and FIGS. 8A-8C, perspective views of one embodimentof a safety vent 350 in both the open and closed positions are shown.Cinch tether 370 circumvents a majority of the perimeter of cinch tube350 in order to properly tighten and restrict the safety vent 350. Cinchtether 370 has a length that includes an initial free length and acircumference of cinch tube 350. Cinch tether 370 may be disposed withina sleeve 353 that is formed within cinch tube 352. Access to the sleeve353 is through a sleeve aperture 354 formed in cinch tube 352. Cinchtether 370 enters sleeve aperture 354, feeds through sleeve 354, and iscoupled at an end within sleeve 353 to cinch tube 352. Coupling may beachieved by stitches, bonds, adhesives, etc. FIG. 6 and FIG. 8C showtether holder 353 gathered together so that rim 351 is collapsed onitself to close cinch tube 352.

Early in a normal inflation, gas loss through safety vent 350 a-b isminimal. This phenomenon is due to the Bernoulli effect—pressure islower in a moving fluid than in a stationary fluid. For example, if theconvex side of a spoon is placed into a smooth stream of water from afaucet, the spoon is pulled into the stream. The higher pressure outsidethe moving fluid pushes the spoon into the lower pressure water. In anairbag deployment, the high velocity stream of gas flowing into thecushion creates a similar effect for approximately 30 milliseconds,particularly in the area of throat 308. Since pressure outside thecushion is still atmospheric, there is a pressure imbalance and airflows into the cushion, not out of the cushion, when the vent ispositioned alongside of the gas flow stream and not in its path.

As discussed above, an advantage of this configuration is that the ventand tether are configured such that upon deployment of the inflatableairbag cushion with obstruction, the tether does not fully extend andthe vent remains open, and upon deployment of the inflatable airbagcushion without obstruction, the tether extends and at least partiallycloses the vent. Full inflation of the inflatable airbag cushion createsa cushion membrane tension that fully extends the tether until reachingthe maximum length of the tether, thereby pulling on the first end ofthe tether and closing the vent. An additional advantage of thisconfiguration is that the vent is configured to close without having toovercome resistance from the cushion membrane tension around the vent.

Another embodiment of an airbag module is depicted at 400 in FIGS.9A-9C. Airbag cushion 401 has closeable safety vents 450 a-b which closeby tether 470 a-b as rim 451 is drawn into the interior 402 of theinflatable airbag cushion 401 in the same manner as vents 350. Since theelements described with reference to safety vent 350 shown in FIGS.7A-7B are identical to the elements of safety vent 450, the samefeatures are identified with like numerals, increased by 100, in FIGS.9A-9C, to the extent that they are shown.

Gas diffuser 480 is configured to create a pressure pocket and re-directthe inflation gas. The embodiment of the gas diffuser shown in FIGS.9A-9C at 480 comprises a material 481 which may be integral with asurface of cushion 401 or attached to cushion 401. For example, gasdiffuser 480 may be sewn together with the cushion. Gas diffuser 480receives gas via throat 408 through opening 482 defined by a perimeter.Direct opening 484, which is defined by perimeter 483, assists withnormal inflation of cushion 401 to assist in getting cushion 401 inposition in time for dynamic loading purposes.

In addition to direct opening 484, gas is also directed out of sideopenings 485 a-485 b. Openings 485 a-b are respectively defined byperimeters or rims 486 a-b at the ends of each arm 487 a-b. In theembodiment shown in FIGS. 9A-9C, a portion of each rim 486 a-b isattached to the cushion membrane 410 so only a portion of the gas isdirected out of the airbag cushion 401 via closeable safety vents 450a-b while another portion of the gas is directed from gas diffuser 480into the interior 402 of airbag cushion 401. Because each arm 487 a-b isattached to the cushion membrane, each arm 487 a-b is configured to moverespectively with closeable safety vents 450 a-b during expansion of theinflatable airbag cushion. Movement together of each arm 487 a-b of gasdiffuser 480 and the respective closeable safety vents 450 a-b duringexpansion of the airbag cushion 401 enables gas exiting the arm to becontinuously directed to the respective closeable vent. In addition topermitting gas to be re-directed into the interior 402 of airbag cushion401 when each closeable safety vent 450 a-b is closed, each opening 485a-b of each arm 487 a-b also permits each tether 470 a-b to extend fromthe respective closeable vent 450 a-b to cushion membrane 420.

Cushion 401 is depicted with each arm attached to cushion membrane at aseam, which acts as vent aligners. Of course, each arm can also beattached to the a respective closeable safety vent. In otherembodiments, a seam between gas diffuser 480 and membrane 410 may not benecessary as the vent tube is an integral extension of the gas diffuser.

Not only are side openings 485 a-b strategically located to redirect thegas flow generally toward closeable vents 450 a-b and out of cushion 401but side openings 485 a-b, are also sized for optimal gas flow. Sideopenings 485 a-b are large enough to allow most of the gas to flowthrough them. Only in out-of-position conditions does the focused gasflow from gas diffuser 480 to the aligned closeable vents 450 a-b toallow a more rapid escape of the inflation gas as shown in FIG. 1A.

As previously indicated, gas diffuser 480 and closeable vents 450 a-bare not independent of each other such that the flow remains aligned orfocused with closeable vents 450 a-b. So if the occupant is in a normalposition and inflation is unrestricted, gas diffuser 480 functions asnormal to re-direct the inflation gas generally toward the vent(s). Thelarge vent(s) are quickly closed as the cushion fully expands retaininggas for normal occupant restraint.

While gas diffuser 480 is T-shaped because arms 487 a-b are directlyopposite each other, other configurations may also be utilized. Forexample, the gas diffuser may be rectangular, trapezoidal, hexagonal,round, etc. It may also have a portion which is round or ellipticalwhile other portions are angled. Additional information about airbagcushions with a diffuser or gas deflector having arms aligned withcloseable safety vents is provided in U.S. patent application Ser. No.11/758,419, which was published as U.S. Patent Publication No.20080303256. U.S. patent application Ser. No. 11/758,419 is herebyincorporated by reference.

FIG. 10 depicts airbag cushion 401′ which differs from airbag cushion400 in that diffuser 480′ is sewn to partition 430′ with threads 434′instead of being tethered together. The other components of airbagcushion 401′ are the same as those of airbag cushion 401.

FIG. 11 and FIGS. 12A-12B depict another airbag module at 500 with adual chamber airbag cushion 501. Like the other embodiments disclosedherein, this embodiment also decouples the restraining force for theoccupant's head and the occupant's chest so that the head is not overrestrained while also restraining the chest. Airbag cushion 501 alsofeatures closeable safety vents 550 and corresponding tethers 570 infront chamber 502 f instead of in back chamber 502 b. One advantage ofcloseable safety vents 550 and tethers 570 is that the restraintprovided by front chamber 502 f can be even more finely controlled thanwith respect to the other embodiments.

Safety vent 550 operates in the same manner as safety vent 350 shown inFIGS. 7A-7B and has the same elements. Since the elements described withreference to safety vent 350 shown in FIGS. 7A-7B are identical to theelements of safety vent 550, the same features are identified with likenumerals, increased by 200, in FIG. 11 and FIGS. 12A-12B, to the extentthat they are shown. For the elements that are not shown in FIG. 11 andFIGS. 12A-12B regarding safety vent 550 reference should be made toFIGS. 7A-7B. The various embodiments of safety vents that can be used inthe back chamber 502 b can also be used in front chamber 502 f. When thehead of an occupant is encountered by front chamber 502 f and obstructsthe deploying airbag cushion 501, full inflation of airbag cushion 501is prevented as shown in FIG. 12A. When airbag cushion 501 impacts anoccupant, tether 570 a (as shown in FIG. 12A) and tether 570 b (notshown in FIG. 12A) remain slack. Closeable safety vents 550 a-b remainopen and venting rapidly occurs from safety vents 550 a-b and discretevents 506. Discrete vents 506 a-b may be located in the side regions 518of cushion 501 near closeable vents 550 a-b, as shown. The cushioninflation is restricted and the occupant receives less than the fulldeployment loading of the front chamber 502 f of cushion 501. Thepartial inflation and resulting limited restraint provides an occupantwith less force to the head and neck while maintaining stronger force tothe chest.

During initial deployment, airbag cushion 501 unfolds and safety vents550 a-b provide little or no venting. As discussed above, airbag cushion501 expands in a manner such that the safety vents 550 a-b will remaincompletely or nearly open and full venting occurs unless front chamber502 f obstructed. If further unobstructed, safety vents 550 a-bcompletely close and an occupant benefits from the full restraintcapability of airbag cushion 501, as shown in FIG. 11 and FIG. 12B.

The partial inflation of front chamber 502 f shown in FIG. 12A and thefull inflation of airbag cushion 501 shown in FIG. 12B the depict thestages of inflation that typically occur. An occupant such as an averagemale, will have some delay in impacting front chamber 502 f comparedwith an average female. The delayed impact of the average male, whichtypically would have a larger mass and is also typically seated furtherfrom the airbag, allows front chamber 502 f enough time to fully inflateto provide adequate cushioning as shown in FIG. 12B. In contrast, thehead of an occupant with a smaller mass, typically seated closer to theairbag rapidly impacts front region 513, particularly upper portion 513u, which causes tether 570 a-b to remain open so that front chamber 502f does not fully inflate. The partial inflation of front chamber 502 fensures that the head of the occupant receives cushioning with lessforce than the occupant's chest does via back chamber 502 b, therebydecoupling the cushioning force that is applied to the head and thechest.

Embodiments disclosed herein illustrate novel techniques for venting anairbag cushion to retain an open vent when an occupant obstructs thepath of a deploying cushion and to close and remain closed when anoccupant does not obstruct a deploying cushion. Airbag cushions provideimproved safety by deploying with less pressure when an occupant isobstructing deployment. The airbag cushions deploy with more pressurewhen an occupant is not obstructing deployment and when high pressure isrequired to provide the necessary restraint. The frontal airbag cushionsdescribed herein have application to both driver and passengerpositions. Furthermore, the airbag cushions may be configured in avariety of sizes based on design constraints. The vent may be closed bybringing the rim of the vent together, at least partially closing thevent and without pulling the rim into the perimeter of the vent.

Various embodiments for closeable vents have been disclosed herein. Thecloseable vents disclosed herein are examples of means for venting gasout of the airbag. A control cord or control tether, as disclosedherein, is an example of means for restricting gas venting by moving thecovering means upon inflatable airbag deployment without obstruction andenabling the vent aperture to remain uncovered upon inflatable airbagdeployment with obstruction. The control tether is also an example ofmeans for restricting gas venting by closing the venting means uponinflatable airbag deployment without obstruction and enabling theventing means to remain open upon inflatable airbag deployment withobstruction.

The combination of a closeable vent and a control tether, as disclosedherein, is an example of means for restricting gas venting by closingthe venting means to reduce the aperture of the venting means uponinflatable airbag deployment without obstruction and enabling theventing means to remain open upon inflatable airbag deployment withobstruction. The combination of a sleeve of a cinch tube and a cinchtether with a plurality of stoppers, as disclosed herein, is an exampleof means for restricting gas venting by incrementally cinching theventing means to reduce the circumference of the venting means uponinflatable airbag deployment without obstruction and enabling theventing means to remain open upon inflatable airbag deployment withobstruction.

It will be apparent to those having skill in the art that changes may bemade to the details of the above-described embodiments without departingfrom the underlying principles of the invention. Embodiments of theinvention in which an exclusive property or privilege is claimed aredefined as follows. Note that elements recited in means-plus-functionformat are intended to be construed in accordance with 35 U.S.C. §112¶6.

1. An airbag module comprising: an inflatable frontal airbag cushion comprising a cushion membrane which defines an interior of the inflatable airbag cushion, wherein the cushion membrane has a front region configured to be directed toward an occupant in a vehicle when the cushion is deployed, wherein the front region has an upper portion and a lower portion, wherein the cushion membrane has a top region above the upper portion of the front region, wherein the cushion membrane has a bottom region below the lower portion of the front region; and a partition comprising a first portion and a second portion, wherein the partition divides the interior of the inflatable airbag cushion into a back chamber and a front chamber; wherein the back chamber is sized to be inflated to a substantially larger volume than the front chamber such that, when inflated, the back chamber extends from the occupant's chest to a windshield of a vehicle; wherein the back chamber is positioned to receive inflation gas directly from an inflator while the front chamber receives inflation gas from the back chamber through the first portion, which is closer to the inflator than the second portion; wherein the front chamber is at least partially defined by the upper portion of the front region and is positioned such that, when inflated, the back chamber is between the front chamber and a windshield of a vehicle to minimize contact between the front chamber and the windshield; whereby the front chamber inflates less rapidly than the back chamber for cushioning the head of an occupant in a vehicle with less force than the chest of an occupant is cushioned by the back chamber.
 2. The airbag module of claim 1, wherein a tether extends from the partition to an interior surface of the airbag cushion.
 3. The airbag module of claim 2, wherein the tether extends from the interior surface of the airbag cushion near an inflator.
 4. The airbag module of claim 1, wherein the partition is integral with the top region of cushion membrane and at least part of the front region.
 5. The airbag module of claim 1, wherein the partition is attached within the airbag cushion to an interior surface of the airbag cushion.
 6. The airbag module of claim 1, wherein the partition has vents to permit inflation gas to move from the back chamber to the front chamber.
 7. The airbag module of claim 1, wherein the partition has sufficient permeability to permit inflation gas to move from the back chamber to the front chamber.
 8. The airbag module of claim 1, further comprising: at least one closeable safety vent; and a tether anchored to the cushion membrane, wherein the tether is configured such that upon deployment of the inflatable airbag cushion with obstruction, the tether does not fully extend and the closeable safety vent remains open, and upon deployment of the inflatable airbag cushion without obstruction, the tether extends and at least partially closes the closeable safety vent.
 9. The airbag module of claim 1, further comprising: at least one closeable safety vent comprising a cinch tube having a base end opposite from a terminal end, wherein the terminal end has an aperture defined by rim; and a tether coupled to the terminal end of the cinch tube and extending around a majority of the aperture of the terminal end of the cinch tube, the tether being further coupled to a surface of the airbag cushion such that upon inflatable airbag deployment with obstruction, the cinch cord does not fully extend and the cinch tube remains open, and upon inflatable airbag deployment without obstruction, the cinch cord extends and at least partially closes the aperture at the terminal end, without necessitating closure of the base end of the cinch tube, such that the terminal end is at least partially within the interior of the inflatable airbag cushion after the aperture becomes at least partially closed.
 10. The airbag module of claim 1, further comprising: at least one closeable safety vent; and a tether connected to the closeable safety vent at a first end and anchored to the cushion membrane at a second end, the first end and the second end separated by a length, wherein the tether is configured such that upon deployment of the inflatable airbag cushion with obstruction, the tether does not fully extend and the vent remains open, and upon deployment of the inflatable airbag cushion without obstruction, the tether extends and at least partially closes the closeable safety vent, wherein full inflation of the inflatable airbag cushion creates a cushion membrane tension that fully extends the second end of the tether until reaching the maximum length of the tether thereby pulling on the first end of the tether and closing the closeable safety vent, and wherein the closeable safety vent is configured to close without having to overcome resistance from the cushion membrane tension around the closeable safety vent.
 11. The airbag module of claim 1, further comprising: at least one closeable safety vent; and at least one closeable vent having an aperture defined by a rim; and a tether connected to the rim of the closeable safety vent at a first end and anchored to the cushion membrane at a second end, wherein the tether is configured such that upon deployment of the inflatable airbag cushion with obstruction, the tether does not fully extend and the closeable safety vent remains open, and upon deployment of the inflatable airbag cushion without obstruction, the tether extends and at least partially closes the closeable safety vent by bringing the rim of the aperture together, wherein full inflation of the inflatable airbag cushion creates a cushion membrane tension that fully extends the second end of the tether until reaching the maximum length of the tether thereby pulling on the first end of the tether and closing the closeable safety vent by bringing the rim of the aperture together, and wherein the rim of the aperture is configured to be brought together without having to overcome resistance from the cushion membrane tension around the closeable safety vent.
 12. The airbag module of claim 1, further comprising a fixed vent disposed on the airbag and adapted to vent gas during airbag deployment with and without obstruction.
 13. The airbag module of claim 1, wherein the partition is positioned such that the front chamber is supported by the back chamber and the front chamber has at least a portion that is partially surrounded by the back chamber.
 14. The airbag module of claim 8, further comprising a gas deflector positioned in the interior of the inflatable airbag cushion to direct inflation gas from an inflator, wherein the gas deflector has an arm configured to permit gas to be re-directed from an inflator to the closeable safety vent, and wherein the arm of the gas deflector and the closeable vent are configured to move together during expansion of the inflatable airbag cushion.
 15. The airbag module of claim 14, wherein movement together of the arm of the gas deflector and the closeable vent during expansion of the airbag enables gas exiting the arm to be continuously directed to the at least one closeable safety vent.
 16. The airbag module of claim 14, wherein the arm terminates at an opening defined by a rim and at least a portion of the rim is attached to the cushion membrane while the remainder of the rim is unattached to the cushion membrane so that gas can be re-directed out of the gas deflector and into the interior of the inflatable airbag cushion when the closeable safety vent is closed.
 17. An airbag module comprising: an inflatable frontal airbag cushion comprising a cushion membrane which defines an interior of the inflatable airbag cushion, wherein the cushion membrane has a front region configured to be directed toward an occupant in a vehicle when the cushion is deployed, wherein the front region has an upper portion and a lower portion, wherein the cushion membrane has a top region above the upper portion of the front region, wherein the cushion membrane has a bottom region below the lower portion of the front region; a partition that divides the interior of the inflatable airbag cushion into a back chamber and a front chamber; a tether extending from the partition to an interior surface of the airbag cushion to maintain the partition in a configuration such that the front chamber has at least a portion that is surrounded by the back chamber; wherein the back chamber is sized to be inflated to a substantially larger volume than the front chamber such that, when inflated, the back chamber extends from the occupant's chest to a windshield of a vehicle; wherein the back chamber is positioned to receive inflation gas directly from an inflator while the front chamber receives inflation gas through the partition from the back chamber; wherein the front chamber is at least partially defined by the upper portion of the front region and is positioned such that, when inflated, the back chamber is between the front chamber and a windshield of a vehicle to minimize contact between the front chamber and the windshield; wherein the partition is positioned such that the front chamber is supported by the base chamber and the front chamber; whereby the front chamber inflates less rapidly than the back chamber for cushioning the head of an occupant in a vehicle with less force than the chest of an occupant is cushioned by the back chamber.
 18. The airbag module of claim 17, wherein the tether extends from the interior surface of the airbag cushion near an inflator.
 19. The airbag module of claim 17, wherein the partition is integral with the top region of cushion membrane and at least part of the front region.
 20. The airbag module of claim 17, wherein the partition has vents to permit inflation gas to move from the back chamber to the front chamber.
 21. The airbag module of claim 17, wherein the partition has sufficient permeability to permit inflation gas to move from the back chamber to the front chamber.
 22. An airbag module comprising: an inflatable frontal airbag cushion comprising a cushion membrane which defines an interior of the inflatable airbag cushion, wherein the cushion membrane has a front region configured to be directed toward an occupant in a vehicle when the cushion is deployed, wherein the front region has an upper portion and a lower portion, wherein the cushion membrane has a top region above the upper portion of the front region, wherein the cushion membrane has a bottom region below the lower portion of the front region; a partition that divides the interior of the inflatable airbag cushion into a back chamber and a front chamber; wherein the partition is sewn to the top region, the front region and the side regions in a configuration such that the front chamber has at least a portion that is surrounded by the back chamber; wherein the back chamber is sized to be inflated to a substantially larger volume than the front chamber such that, when inflated, the back chamber extends from the occupant's chest to a windshield of a vehicle; wherein the back chamber is positioned to receive inflation gas directly from an inflator while the front chamber receives inflation gas through the partition from the back chamber; wherein the front chamber is at least partially defined by the upper portion of the front region and is positioned such that, when inflated, the back chamber is between the front chamber and a windshield of a vehicle to minimize contact between the front chamber and the windshield; wherein the partition is positioned such that the front chamber is supported by the base chamber and the front chamber; whereby the front chamber inflates less rapidly than the back chamber for cushioning the head of an occupant in a vehicle with less force than the chest of an occupant is cushioned by the back chamber.
 23. The airbag module of claim 22, wherein the front region is integral with the top region and with the bottom region.
 24. The airbag module of claim 22, wherein the partition has vents to permit inflation gas to move from the back chamber to the front chamber.
 25. The airbag module of claim 22, wherein the partition has sufficient permeability to permit inflation gas to move from the back chamber to the front chamber. 